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Single-rotor Wankel engine v1

A single-rotor Wankel engine assembly with these parts: a trochoid rotor housing (R=65, e=10) with peripheral intake/exhaust ports and a spark plug boss, a triangular rotor 40 wide with apex slots, side seal grooves, combustion recesses and an internal 60T phasing gear, a stationary external 40T gear, an eccentric shaft Ø30 with a Ø50 lobe, two end housings with 6006 bearings, two counterweights and the through-bolts.

Files

STEP · AP214Exact solids for CAD/CAM STLMesh for 3D printing Drawing PDFA3, sections, hole & weld tables DXF flat patternsLaser / plasma cutting, zip

Flagged by the engineer

The flank arc is an approximation of the true inner envelope. Compression ratio and exact clearance must be verified with the exact envelope curve.
The stationary gear wall is thin (bore 32 vs root Ø37.5).
Apex seals, side seals, cooling passages and lubrication are not modelled. S235 is unsuitable for the trochoid running surface, which needs a hard coating (e.g. Nikasil).
Tooth phase alignment of the gear mesh is not verified in the shown pose.

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Specification

Generating radius R	65 mm
Eccentricity e	10 mm
K = R/e	6.5
Phasing gears	m1, 40T / 60T internal
Rotor : shaft speed	1 : 3
Rotor width	40 mm
Overall size	220 × 212 × 200 mm
Parts	26
Material	Steel (S235)
Mass (calculated)	26558.4 g
General tolerance	± 0.2 mm (ISO 2768-m)
Process	machining

Standard parts · purchasable

2×	Deep groove ball bearing 6006 ISO 15
8×	Plain washer M8 ISO 7089
4×	Socket head cap screw M8x100 ISO 4762
4×	Hexagon nut M8 ISO 4032

Parts list

01	rotor_housing 220 × 212 × 40.4 mm · 9123.4 g
02	end_housing_front 220 × 200 × 20 mm · 6495.0 g
03	end_housing_rear 220 × 200 × 20 mm · 6495.0 g
04	rotor 105.83 × 110.33 × 40 mm · 1684.6 g
05	stationary_gear 41.99 × 41.99 × 9.7 mm · 33.5 g
06	eccentric_shaft 50 × 50 × 200 mm · 1405.7 g
07	bearing_front 55 × 55 × 13 mm · 135.6 g
08	bearing_rear 55 × 55 × 13 mm · 135.6 g
09	counterweight_front 55 × 110 × 12 mm · 414.3 g
10	counterweight_rear 55 × 110 × 12 mm · 414.3 g
11	washer_top_0 16 × 16 × 1.6 mm · 1.8 g
12	bolt_0 13 × 13 × 108 mm · 46.6 g
13	washer_bot_0 16 × 16 × 1.6 mm · 1.8 g
14	nut_0 14.61 × 13 × 6.8 mm · 5.1 g
15	washer_top_1 16 × 16 × 1.6 mm · 1.8 g
16	bolt_1 13 × 13 × 108 mm · 46.6 g
17	washer_bot_1 16 × 16 × 1.6 mm · 1.8 g
18	nut_1 14.61 × 13 × 6.8 mm · 5.1 g
19	washer_top_2 16 × 16 × 1.6 mm · 1.8 g
20	bolt_2 13 × 13 × 108 mm · 46.6 g
21	washer_bot_2 16 × 16 × 1.6 mm · 1.8 g
22	nut_2 14.61 × 13 × 6.8 mm · 5.1 g
23	washer_top_3 16 × 16 × 1.6 mm · 1.8 g
24	bolt_3 13 × 13 × 108 mm · 46.6 g
25	washer_bot_3 16 × 16 × 1.6 mm · 1.8 g
26	nut_3 14.61 × 13 × 6.8 mm · 5.1 g